I will be editing this thread as I generate more data..
These measurements are helpful to verify your DJ0228 needle - For performance and fueling measurements, please see - https://www.kawasakiforums.com/forum...-teaser-43153/

Below:
Needle on Left - Stock 2012 KLX250S
Needle on Right- DynoJet #228 from Kit #2152



Below and next 3 pictures:
Measurement of DJ clip, washers, and "Retainer" on stock needle:
As can be seen, the 2 washers+clip add up to .057.
The stock Retainer is .0615




Below:
Length of Stock Needle from bottom of retainer to tip = 2.31 Inches

 

Looks like several of the pictures are not loading.

Thanks for posting this! I'll be measuring mine tonight to verify.

Once I get my N1TC in I'll measure that up as well.

 

That's the part that sucks about Keihin and DJ - no measurement information easily found. Mikuni has all their needles dimensioned at given intervals on the needles in most cases. The pumper needles are different for some reason...

 

Below:
DJ 228 Needle length using 1.5N = 2.28 inches. That is clip on top notch with one washer below and one washer above.
So, length @ 1N would be 2.301 - slightly shorter than the stock NNLA needle (2.31)


Below:
Diameter of DJ needle about .05" from end. About .048"
Stock needle @ .05" is .51"


Below:
DJ needle at about .2" up from tip = .049"
Stock needle @ .2 is .058"


Below:
Diameter of DJ needle about .4" from tip = .057"
Stock needle @ .4 is .061"


Additional DJ 0228 measurements from PWJM:

@0.05” 0.0455"
@0.2” 0.049"
@0.4” 0.0565"
@0.5” 0.059 "
@0.8” 0.0725"
@1” 0.080 "

Below:
A shot of the DJ needle in the 2206 kit(KLX300R) - DN0352




And for more information - here is a shot of the N1TC needle:

 

You are, without a doubt, the worlds foremost expert on Dynojet for the KLX250s.

 

My measurements from yesterday as well:

2152 Needle:

DJ Clip: 0.0115 in
DJ Washer: 0.0175 in
Needle tip: 0.047 in
@0.05” 0.0455 in 0.046
@0.2” 0.049 in 0.048
@0.4” 0.0565 in 0.058
@0.5” 0.059 in 0.061
@0.8” 0.0725 in
@1” 0.080 in 0.0805
Shank 0.091 in
tip length 0.011 in

 

The idea with this thread is that a person could verify the dimensions on the DNO228 needle that comes in the DJ 2152 kit. For troubleshooting purposes.

 

You know, you could compare your measurements to the Mikuni needles, you might find ones that will squeeze between your DJ numbers to solve jetting issues. After all, if all the fit sizes work the carb won't care if it's DJ, Kiehin, or Mikuni as long as it fits. More variety to work with.

 

This is great info. Thanks for starting the thread.

I know you have considerable experience with jetting/carb setup. Do you have any needle+jetting combo recommendations for the KLX (in 250 trim wi open exhaust the only mod) based on your experience? When I got my '06, it had the DN0352 needle with a DJ132 main. I didn't know any better & assumed the needle was stock, so bought the DJ 2102 kit & installed the 228 needle & 128 main jet (per the DJ instructions in kit). The po ole thing wouldn't get out of its own way! Really killed the power throughout the band, so I quickly put the original needle (352) and the original main (132) back in it.

Based on your experience, would you estimate the huge difference in power between the two setups was due to the main, or the needle? And could I expect even better performance with the 352 needle and an even larger main?
Appreciate your thoughts.

 

Well, I need a little more information.
As per your experience and as can be seen in this thread, the 352 needle is totally different from the 228 - providing a different fueling curve.

What altitude do you ride at ?
What do you mean by "open exhaust"?
Exactly how is your airbox configured - e.g. Is there some kind of snorkel?

How much do you know of the bikes' history pertaining to modifications:
Is it possible that it is no longer a 250 but is running a big bore kit - 300, 331, 351 etc..
Could it be that someone, in the bikes' past, could have retimed the cams a la Marcelino Cam Mod ( MCM )?
Could it be possible that it is running performance cams?
Does it carry the stock sprockets?

Your information and observations are REALLY important to all of us in here that are pondering 2206 vs 2152 .